Heater and Liquid Transport for an Aerosol Delivery System

This application is a continuation of U.S. patent application Ser. No. 16/598,505, titled Heater and Liquid Transport for an Aerosol Delivery System, filed on Oct. 10, 2019, which claims priority to, and the benefit of, U.S. Provisional Patent Application No. 62/744,978, titled Aerosol Forming Device, filed on Oct. 12, 2018, each of which is incorporated herein in its entirety by reference.

The present disclosure relates to aerosol delivery devices such as smoking articles, and more particularly to aerosol delivery devices that may utilize electrical power for the production of aerosol (e.g., smoking articles commonly referred to as electronic cigarettes). The smoking articles may be configured to vaporize an aerosol precursor, which may incorporate materials that may be made or derived from tobacco or otherwise incorporate tobacco, the precursor being capable of forming an inhalable substance for human consumption.

Many smoking devices have been proposed through the years as improvements upon, or alternatives to, smoking products that require combusting tobacco for use. Many of those devices purportedly have been designed to provide the sensations associated with cigarette, cigar, or pipe smoking, but without delivering considerable quantities of incomplete combustion and pyrolysis products that result from the burning of tobacco. To this end, there have been proposed numerous smoking products, flavor generators, and medicinal inhalers that utilize electrical energy to vaporize or heat a volatile material, or attempt to provide the sensations of cigarette, cigar, or pipe smoking without burning tobacco to a significant degree. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat generating sources set forth in the background art described in U.S. Pat. No. 7,726,320 to Robinson et al., U.S. App. Pat. App. Pub. No. 2013/0255702 to Griffith Jr. et al., and U.S. Pat. App. Pub. No. 2014/0096781 to Sears et al., which are incorporated herein by reference in their entireties. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered heat generating sources referenced by brand name and commercial source in U.S. patent application Ser. No. 14/170,838 to Bless et al., filed Feb. 3, 2014, which is incorporated herein by reference in its entirety. It would be desirable to provide an aerosol delivery device with advantageous usability features.

The present disclosure relates to aerosol delivery devices, methods of forming such devices, and elements of such devices. The disclosure particularly relates to an aerosol delivery device. In this regard, various embodiments of the disclosure provide an aerosol delivery device with advantageous usability features. The present disclosure includes, without limitation, the following example implementations:

An aerosol delivery device comprising a control device that includes an outer housing defining an outer wall and having a proximal end and a distal end, the proximal end of the control device defining a cartridge receiving chamber, the control device further including a power source and a control component, and a cartridge that includes a mouthpiece portion and a tank portion, the mouthpiece portion and the tank portion having respective proximal and distal ends, the tank portion being configured to contain a liquid composition, the cartridge further including an atomizing member and a liquid transport element, wherein a portion of the cartridge is configured to be removably coupled with the cartridge receiving chamber of the control device, wherein at least a portion of the liquid transport element is located proximate the atomizing member, wherein the atomizing member is configured to vaporize the liquid composition to generate an aerosol, and wherein at least a portion of the atomizing member is positioned above the proximal end of the tank portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the atomizing member comprises a heating member, and wherein the heating member is configured to heat the liquid composition to generate the aerosol.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, the cartridge further including a second liquid transport element, and wherein the second liquid transport element is configured to transport liquid to the first liquid transport element.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein at least a portion of the heating member is positioned between the distal end of the mouthpiece portion and the proximal end of the tank portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the cartridge further includes a collar portion disposed between the mouthpiece portion and the tank portion, and wherein at least a portion of the heating member is located within the collar portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a flat heating member installed in a curved orientation, wherein the second liquid transport element defines a longitudinal portion that intersects a curved transverse portion, and wherein a length of the longitudinal portion of the second liquid transport element is longer than a length of the transverse portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, further comprising a curved hood feature, wherein the curvature of the hood feature opposes the curvature of the heating member.

The aerosol delivery device of any preceding example implementations, or any combination of any preceding example implementations, wherein the heating member comprises a flat heating member installed in a curved orientation, wherein the second liquid transport element defines a longitudinal portion that intersects a curved transverse portion, and wherein a length of the transverse portion of the second liquid transport element is longer than a length of the longitudinal portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, further comprising a curved hood feature, wherein the curvature of the hood feature opposes the curvature of the heating member.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a coil heating member, wherein the first liquid transport element has a U-shape defining a central portion and two opposite leg portions, wherein a portion of the heating member is wrapped around at least the central portion of the first liquid transport element, wherein the second liquid transport element defines a longitudinal portion that intersects a transverse portion, and wherein a length of the longitudinal portion of the second transport element is longer than a length of the transverse portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a coil heating member, wherein the first liquid transport element has a U-shape defining a central portion and two opposite leg portions, wherein a portion of the heating member is wrapped around at least the central portion of the first liquid transport element, wherein the second liquid transport surrounds both of the legs of the first liquid transport element, and wherein a length of the legs of the first liquid transport element is longer than a length of the central portion of the first liquid transport element.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a coil heating member, wherein the first liquid transport element has a cylindrical shape and is substantially aligned with a longitudinal axis of the cartridge, wherein a portion of the heating member is wrapped around at least a portion of the first liquid transport element, and wherein the second liquid transport element has a cylindrical shape and is substantially aligned with a longitudinal axis of the cartridge.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the second liquid transport element is substantially solid, and wherein a length of the second liquid transport element is longer than a length of the first liquid transport element portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the second liquid transport element is hollow, wherein the second liquid transport element surrounds at least a portion of the first liquid transport element, and wherein a length of the first liquid transport element is longer than a length of the second liquid transport element.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the first liquid transport element is hollow and comprises a ceramic material.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the first liquid transport comprises at least one of a cotton material and a silica material.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a coil heating member, wherein the first liquid transport element has a cylindrical shape and is substantially aligned with a longitudinal axis of the cartridge, wherein a portion of the heating member is embedded within at least a portion of the first liquid transport element, and wherein the second liquid transport element has a cylindrical shape and is substantially aligned with a longitudinal axis of the cartridge.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the second liquid transport element is substantially solid, and wherein a length of the second liquid transport element is longer than a length of the first liquid transport element portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the second liquid transport element is hollow, wherein the second liquid transport element surrounds at least a portion of the first liquid transport element, and wherein a length of the first liquid transport element is longer than a length of the second liquid transport element.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a flat heating member, wherein the second liquid transport element comprises a plurality of capillary tubes, wherein the heating member and the first liquid transport element are substantially aligned with a transverse axis of the cartridge, and wherein the plurality of capillary tubes are substantially aligned with a longitudinal axis of the cartridge.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the plurality of capillary tubes comprises a pair of spaced capillary tubes.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the plurality of capillary tubes comprises five spaced capillary tubes arranged in a cross pattern.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a flat heating member, wherein the second liquid transport element defines a longitudinal portion that intersects a transverse portion, and wherein a length of the longitudinal portion of the second liquid transport element is longer than a length of the transverse portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the cartridge further includes a collar portion disposed between the mouthpiece portion and the tank portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the atomizing member is located at least partially within the collar portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the atomizing member comprises a heating member configured to heat the liquid composition to generate the aerosol, and further comprising a hood feature positioned proximate the heating member, wherein the hood feature is located at least partially within the mouthpiece portion.

An aerosol delivery device comprising a control device that includes an outer housing defining an outer wall and having a proximal end and a distal end, the proximal end of the control device defining a cartridge receiving chamber, the control device further including a power source and a control component, and a cartridge that includes a mouthpiece portion and a tank portion, the mouthpiece portion and the tank portion having respective proximal and distal ends, the tank portion being configured to contain a liquid composition, the cartridge further including a first liquid transport element, a second liquid transport element, and an atomizing member, wherein a portion of the cartridge is configured to be removably coupled with the cartridge receiving chamber of the control device, wherein the atomizing member is configured to vaporize the liquid composition to generate an aerosol, wherein at least a portion of the atomizing member is positioned between the proximal end of the tank portion and the distal end of the tank portion, wherein at least a portion of the first liquid transport element is positioned below the atomizing member, wherein the second liquid transport element is disposed below the first liquid transport element, and wherein the second liquid transport element is configured to transport liquid to the first liquid transport element.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the atomizing member comprises a heating member, and wherein the heating member is configured to heat the liquid composition to generate the aerosol.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a flat heating member, and wherein the heating member is positioned proximate the distal end of the tank portion.

An aerosol delivery device comprising a control device that includes an outer housing defining an outer wall and having a proximal end and a distal end, the proximal end of the control device defining a cartridge receiving chamber, the control device further including a power source and a control component, and a cartridge that includes a mouthpiece portion and a tank portion, the mouthpiece portion and the tank portion having respective proximal and distal ends, the tank portion being configured to contain a liquid composition, the cartridge further including an atomizing member and a liquid transport element, wherein a portion of the cartridge is configured to be removably coupled with the cartridge receiving chamber of the control device, wherein at least a portion of the liquid transport element is located proximate the atomizing member, wherein the atomizing member is configured to vaporize the liquid composition to generate an aerosol, and wherein at least a portion of the atomizing member is positioned proximate the distal end of the mouthpiece portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the atomizing member comprises a heating member, and wherein the heating member is configured to heat the liquid composition to generate the aerosol.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, the cartridge further including a second liquid transport element, and wherein the second liquid transport element is configured to transport liquid to the first liquid transport element.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a flat heating member installed in a curved orientation, wherein the second liquid transport element defines a longitudinal portion that intersects a curved transverse portion, and wherein a length of the longitudinal portion of the second liquid transport element is longer than a length of the transverse portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, further comprising a curved hood feature, wherein the curvature of the hood feature opposes the curvature of the heater.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a flat heating member installed in a curved orientation, wherein the second liquid transport element defines a longitudinal portion that intersects a curved transverse portion, and wherein a length of the transverse portion of the second liquid transport element is longer than a length of the longitudinal portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, further comprising a curved hood feature, wherein the curvature of the hood feature opposes the curvature of the heater.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a coil heating member, wherein the first liquid transport element has a U-shape defining a central portion and two opposite leg portions, wherein a portion of the heating member is wrapped around at least the central portion of the first liquid transport element, wherein the second liquid transport element defines a longitudinal portion that intersects a transverse portion, and wherein a length of the longitudinal portion of the second transport element is longer than a length of the transverse portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a coil heating member, wherein the first liquid transport element has a U-shape defining a central portion and two opposite leg portions, wherein a portion of the heating member is wrapped around at least the central portion of the first liquid transport element, wherein the second liquid transport surrounds both of the legs of the first liquid transport element, and wherein a length of the legs of the first liquid transport element is longer than a length of the central portion of the first liquid transport element.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a coil heating member, wherein the first liquid transport element has a cylindrical shape and is substantially aligned with a longitudinal axis of the cartridge, wherein a portion of the heating member is wrapped around at least a portion of the first liquid transport element, and wherein the second liquid transport element has a cylindrical shape and is substantially aligned with a longitudinal axis of the cartridge.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the second liquid transport element is substantially solid, and wherein a length of the second liquid transport element is longer than a length of the first liquid transport element portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the second liquid transport element is hollow, wherein the second liquid transport element surrounds at least a portion of the first liquid transport element, and wherein a length of the first liquid transport element is longer than a length of the second liquid transport element.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the first liquid transport element is hollow and comprises a ceramic material.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the first liquid transport element comprises at least one of a cotton material and a silica material.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the heating member comprises a coil heating member, wherein the first liquid transport element has a cylindrical shape and is substantially aligned with a longitudinal axis of the cartridge, wherein a portion of the heating member is embedded within at least a portion of the first liquid transport element, and wherein the second liquid transport element has a cylindrical shape and is substantially aligned with a longitudinal axis of the cartridge.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementation, wherein the second liquid transport element is substantially solid, and wherein a length of the second liquid transport element is longer than a length of the first liquid transport element portion.

The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the second liquid transport element is hollow, wherein the second liquid transport element surrounds at least a portion of the first liquid transport element, and wherein a length of the first liquid transport element is longer than a length of the second liquid transport element.